Belt troubles in an 06 rev

[summitX]

This might get a bit long but i'm not sure what to do. First off here is the problem, i cant get a belt to last in my 06 summit 800. Last year i had a 383 which was junk and now i picked up a couple of 377 belts. I broke in one 377 real easy for about fifty miles (trail riding) and then started pulling some hills and powder riding. The belt lasted for two days and then cords were flying out of it.

Now i have attempted to shim my secondary properly. I believe plus or minus 1.5 mm difference from the front to the back of the primary with a straight bar in the secondary. The problem that i'm having is that i can set the 3/8" bar in the secondary and pinch it and get the measurements right on the primary but then rotate the secondary clutch 180 degrees and do the same procedure and have totally different measurements. This leads me to believe that my jackshaft might be bent or out of round. Does that sound possible?

Another thing to note, when i have the sled lifted off the ground and run the engine slowly at speeds less than approximately 20 mph the secondary appears to wobble as it spins.

So a couple questions: Is it possible to bend a jackshaft? Are there some sort of bushings in the secondary that could be worn beyond the limit and cause this symptom?

Any help would be greatly appreciated because these damn belts arn't cheap!
Thanks!

 

[Danzick]

well unless you really know what you are doing, id take it to a dealership for alignment. it costed me like 30 dollars to have it done, and yes there is some bushings in the secondary that run on the helix. not sure if them wearing leads to a wobly secondary tho. ive never heard of that long shaft bending. i dont know how a person could even do it. i would go through both clutches and make sure they are all good. you can use a drill press to pull the secondary apart. and there is a torque stopper that is a tough rubber, and it sits against the frame between the secondary and primary. i was blowing belts because this torque stopper rattled out, and when i got on it hard it would throw my clutches out of alignment and cause belts to blow.

 

[brahm]

you can float the secondary, and/or look for 166 belts on ebay. I just started to pull thread on my last 166, bought a 383 (cost me 120$ from my local dealer!).. went on ebay and bought 3 new 166 belts ranging from 40-60 a pop. Hopefully they will last me a couple seasons.

 

[winter brew]

Run the sled with the shield off and watch the secondary to verify if anything is bent.
IMO the best belt for the rev is a -288.

 

[summitX]

I have ran the sled with the track in the air and the guard off. The secondary seems to open correctly when the primary is closing but at a slower speed say idle to 20 mph the secondary has a wobble that you can visually see. After approximately 20 mph the wobble seems to go away. Also my torque stopper is adjusted so it rests on the engine.

When i bought the sled last fall i had the secondary and primary apart to put in a clutch kit. If i recall right I also put new buttons in the secondary. I usually take the primary apart 3-4 times a year to clutch for the mountains and check things over but usually not the secondary. I have heard about floating the secondary but have never seen how to do it. Can someone describe what needs to be done, i have acess to a lathe and most likely whatever else is needed.

Thanks

 

[Dynamo^Joe]

Check the small and large bushing measurements.
Also the torque stop should be adjusted tight enough that you can have a piece of paper stuck between it and tightly pull it out.

Measure primary sliding sheave bushing

 

[summitX]

I will check the bushing measurements this weekend when i'm around my sled and post back my findings.

Thanks!

 

[POPPS]

The wobble bothers me. I doubt if you have a dial indicator so maybe you could clamp a straight edge so the end is near the outer edge of the secondary and with the sled on the stand rotate the secondary by hand. If there is a wobble this will show it.

 

[summitX]

I am actually planning on borrowing a dial indicator from a buddy this weekend and check the run out just past the splined section on the jackshaft. I figured that was a positive way to rule out a bent shaft.